Gema OptiSpray AP01.1 Operating Instructions Manual Download

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Rev. 00

1011

525

Operating instructions and spare parts list

OptiSpray AP01.1

Application Pump

Translation of the original operating instructions

Summary of Contents for OptiSpray AP01.1

Page 1: ...Rev 00 1011 525 EN Operating instructions and spare parts list OptiSpray AP01 1 Application Pump Translation of the original operating instructions ...

Page 2: ...mes are trademarks or registered trademarks of their respective holders Reference is made in this manual to different trademarks or registered trademarks Such references do not mean that the manufacturers concerned approve of or are bound in any form by this manual We have endeavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders To the best o...

Page 3: ...matic data 10 Powder output guide values 11 Dimensions 11 Sound pressure level 11 Rating plate 12 Design and function 13 General view 13 Powder hoses 13 Spraying air function diffusers 14 Connections 15 Scope of delivery 15 Typical properties functional characteristics 16 Main functions 16 Secondary functions 16 Conveying direction 16 Powder hose rinsing 16 Maintenance interval monitoring 17 Assem...

Page 4: ...32 Replacing the filter elements 33 Replacing the Application pump in an OptiCenter 34 Fault clearance 35 Decommissioning Storage 37 Decommissioning 37 If in disuse for several days 37 Storage conditions 37 Hazard notes 37 Type of storage 37 Storage duration 37 Space requirements 37 Physical requirements 38 Maintenance during storage 38 Maintenance schedule 38 Maintenance works 38 Disposal 39 Intr...

Page 5: ... documents Keeping the Manual Please keep this Manual ready for later use or if there should be any queries Safety symbols pictograms The following warnings with their meanings can be found in the Gema operating instructions The general safety precautions must also be followed as well as the regulations in the relevant operating instructions DANGER Indicates a hazardous situation which if not avoi...

Page 6: ...es a potentially harmful situation which if not avoided may have harmful consequences for the environment MANDATORY NOTE Information which must be observed NOTE Useful information tips etc Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text Example The high voltage H created in the gun cascade is guided through the cente...

Page 7: ...substances outside of our guidelines then Gema Switzerland GmbH should be consulted Start up i e the execution of intended operational tasks is forbidden until it has been established that this product has been set up and wired according to the guidelines for machinery The standard Machine safety must also be observed Unauthorized modifications to the product exempt the manufacturer from any liabi...

Page 8: ... that all components are earthed according to the local regulations before start up For further security information see the more detailed Gema safety regulations WARNING Working without instructions Working without instructions or with individual pages from these instructions may result in damage to property and personal injury if relevant safety information is not observed Before working with th...

Page 9: ...omatic gun or with other Gema models with a suitable diffuser spraying air adapter Please contact Gema if you have any further queries fig 1 Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the p...

Page 10: ...ompressed air quality Input pressure too low Use in connection with unauthorized coating devices or components Technical Data Electrical data OptiSpray AP01 1 Nominal input voltage 24 VDC Output 10 VA Protection type IP54 Temperature range 15 C 40 C 59 F 104 F Temperature class T6 Approvals II 3 D Pneumatic data OptiSpray AP01 1 Compressed air connection Quick release connection 8 mm Inlet pressur...

Page 11: ...ule without connections 275 mm Width 40 mm Depth 183 mm Weight basic module without connections 3 2 kg Sound pressure level OptiSpray AP01 1 Normal operation 60 dB A The sound pressure level was measured while the unit was in operation measurements were taken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicable only for this product its...

Page 12: ...Rev 00 05 17 12 Product description OptiSpray AP01 1 Rating plate fig 2 ...

Page 13: ... transport side 5 Pneumatic system and electronics Powder hoses Depending the application different powder hoses are used for the suction and conveying procedure The corresponding hose connections with nuts with kink protection must be used Field of application Suction side Conveyance side In OptiCenter OC03 OC05 Inside diameter 4 5 mm OptiCenter suction tube hose max 30 cm Inside diameter 7 mm In...

Page 14: ... conductive Spraying air function diffusers The coating guns to be used must be equipped with the appropriate spraying air function or with an appropriate diffuser adapter fig 4 Air streams in the diffuser adapter GL Total air TL Transport air ZL Spraying air P Gun The OptiGun GA02 automatic gun and the OptiSelect GM03 manual gun must also be equipped with an appropriate diffuser adapter The diffu...

Page 15: ...r hoses cables Connection Description 1 1 Compressed air Air Supply IN connection 1 2 Transport air Conveying Air IN connection 1 6 Pinch valve air connection 2 5 External signal connection Pin assignment Connection 2 5 Ext 12 pins A H Control signal J M 24 VDC Body grounding PE Scope of delivery Mains cable Operating manual ...

Page 16: ...ction of arrow that means the suction side is on the bottom the transport side on the top see picture Powder hose rinsing The powder hose rinsing enables the cleaning of the powder hoses and the filter elements in the Application pump If color changes take place rinsing must be done in conveying and in suction direction Cleaning programs The OptiStar Gun control unit features three cleaning progra...

Page 17: ... cleaning procedure The Ultra sonic sieve can be damaged during cleaning when being used with an OptiCenter Only the original lid without any sieve insert must be assembled and closed on the OptiSpeeder The pump is to be cleaned as a component of the entire system Maintenance interval monitoring This function is provided by the OptiStar CG12 CP or the CG11 P Control unit ...

Page 18: ...Rev 00 05 17 18 Product description OptiSpray AP01 1 ...

Page 19: ...5 Powder management center or as a part of the OptiFlex 2 Spray B or F manual equipment fig 6 ATTENTION Surrounding temperature too high Install the Application pump only in locations with an ambient temperature of between 15 and 40 C i e never next to heat sources such as an enameling furnace or electromagnetic sources such as a control cabinet ...

Page 20: ...cturer Just a few cables and hoses must be connected fig 7 Connection instructions overview 1 Electrode rinsing air hose 2 Powder hose 3 Gun cable 4 Pinch valve air 5 Spraying air hose 6 Transport air hose 7 Control signal cable 8 Application pump no 1 8 1 Application pump no 2 9 Gun control 10 Compressed air hose 11 Hose coupling Ø 8 6 Ø 6 4 mm 12 Powder container ...

Page 21: ...21 Connect grounding cable to the booth or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less The compressed air must be free of oil and water Close the unused connections with the provided dust protection caps ...

Page 22: ...Rev 00 05 17 22 Assembly Connection OptiSpray AP01 1 ...

Page 23: ... preparation and powder quality Basic information The adherence of the following principles leads to a successful start up of the Application pump The suction distance is to be kept as short as possible Basically the powder transport with the Application pump works with every powder type which can be fluidized If the powder is for example humid or contaminated with other materials then the conveyi...

Page 24: ...Rev 00 05 17 24 Start up OptiSpray AP01 1 ...

Page 25: ...tched on and off by the pump control see the corresponding operating manual Switching on and off the rinsing procedure The rinsing procedure is switched on and off by the pump control see the corresponding operating manual For a better understanding of the interrelationships in powder coating it is recommended to read completely the operating instructions of the control unit and the powder gun so ...

Page 26: ...Rev 00 05 17 26 Operation OptiSpray AP01 1 ...

Page 27: ...ny liability from resulting damage Regular careful cleaning and maintenance extends the service life of the product and ensures long lasting uniform coating quality The parts to be replaced during maintenance work are available as spare parts For further information see chapter Spare parts list General information The product is designed in such a way that only a minimum maintenance is required ...

Page 28: ...er hoses are avoided Pinch valve diagnostic The pinch valve diagnostic is to be carried out in order to maintain the coating quality or after the error message H89 is displayed The prerequisites for the diagnostic Exhaust at suction and conveyance side must be present and in operation Powder hopper must be empty Cleaning program completed The pinch valve diagnostic is to start after the cleaning p...

Page 29: ...e rinsing procedure can be started and stopped only externally via control unit or plant control The Application pump must be cleaned at least once per shift Periodic checks The periodic checks include examining all connecting cables and hoses The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered All plugs must be properly tightened ...

Page 30: ...cialist Improper tampering can result in serious danger for user and equipment Replacing the pinch valve hoses and filter elements Before dismantling changing the filter elements it is necessary to clean the Application pump in both directions by using the rinsing program Required spare parts AP01 1 Service set Gema order no 1015 435 fig 8 1 Filter element 2 Pinch valve hose 3 Fluid blocking ring ...

Page 31: ... 05 17 OptiSpray AP01 1 Maintenance Repairs 31 Required Tools fig 9 1 Dismantling tool Order number 1012 909 2 Open ended wrench 16 mm 3 Allen key size 4 mm 4 Allen key size 3 mm Pump disassembly 1 2 3 4 5 6 ...

Page 32: ...ct inserted pinch valve hose causes malfunctions It is imperative to consider the position of the lens shaped opening Make sure that the positioning tabs are set correctly 6 ATTENTION Broken pinch valve hose may cause the clogging of the fluid blocking plate Clean or replace the corresponding fluid blocking plate ...

Page 33: ...nzine light lye or acid or a cleaning agent 1 2 ATTENTION Incorrectly assembled parts may cause malfunctions or defects The assembly takes place in reverse order The tightening torques are to be observed when assembling The process zone has to be pressed against a planar surface and assembled on it 3 4 5 6 Operate the Application pump with powder at least 1 2 hour after replacing the filter elemen...

Page 34: ...01 1 Replacing the Application pump in an OptiCenter 1 Remove the powder from the system 2 Start the cleaning program rinse in both directions 3 Depressurize vent OptiCenter 4 Next steps are described in the corresponding OptiCenters operating manual ...

Page 35: ...tion Service life of the pinch valve has expired defective Change the pinch valve check the pneumatic system for defects and replace if necessary Service life of the filter element runs off clogged Replace the filter element Application pump conveys irregularly or too little powder Pinholing in the powder container powder will not be fluidized well Adjust the fluidization correctly Hose backpressu...

Page 36: ...lt clearance OptiSpray AP01 1 Incident Causes Corrective action Transport air offset C3 not adapted to powder output Adapt transport air offset C3 see operating manual OptiStar CG12 CP or CG11 P section Correction values ...

Page 37: ...see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a horizontal position Storage duration If the physical conditions are maintained the unit can be stored indefinitely Space requ...

Page 38: ...ents Storage must be inside a dry building at a temperature between 5 and 50 C Do not expose to direct sunlight Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Page 39: ...of properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and taken to the appropriate collection points Disassembly of component groups WARNING Live components Risk of fatal injury from electric shock if touched On...

Page 40: ...Rev 00 05 17 40 Disposal OptiSpray AP01 1 ...

Page 41: ... 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Use of non original Gema spare parts When using...

Page 42: ...56 15 Nut with kink protection M16x1 Ø 12 mm 1005 443 16 Elbow connection 1010 051 17 Allen cylinder screw M5x20 mm 222 950 18 Allen cylinder screw M4x12 mm 216 275 19 O ring Ø 10x2 mm 243 000 20 Plug 1010 052 21 O ring Ø 16x2 mm 1007 794 22 Suction tube 1010 053 23 O ring Ø 6 1 mm 217 115 24 Hose connection Ø 11 5 7 mm 1010 371 25 Screw in nipple 1 8 Ø 8 mm 1010 378 26 Connection plug 200 859 27 ...

Page 43: ...Rev 00 05 17 OptiSpray AP01 1 Spare parts list 43 OptiSpray AP01 1 spare parts fig 10 Item Tightening torque Nm 1 4 4 greased 4 3 1 greased 7 4 4 greased 17 3 1 18 0 5 ...

Page 44: ...lue 103 497 1 6 Plastic tube Ø 8 6 mm green 103 519 2 5 Connecting cable 12 pins 1 5 m 1000 991 Connecting cable 12 pins 2 2 m 393 398 Connecting cable 12 pins 5 m 1000 975 Connecting cable 12 pins 10 m 1000 976 Connecting cable 12 pins 15 m 1000 977 Connecting cable 12 pins 20 m 1000 978 Please indicate length fig 11 Connecting material ...

Page 45: ... during storage 38 Maintenance interval monitoring 17 Maintenance of the dense phase pump 28 Maintenance schedule 28 O Operation 25 P Periodic checks 29 Pictograms 5 Pin assignment 15 Pinch valve diagnostic 28 Pneumatic data 10 Powder hose rinsing 16 Powder hoses 13 Powder output guide values 11 Preparation for start up 23 Presentation of the content Figure references in the text 6 Presentation of...

Page 46: ...tiSpray AP01 1 Spraying air function diffusers 14 Start up 23 Storage 37 Storage conditions 37 Switching on and off Conveying procedure 25 Rinsing procedure 25 T Technical Data 10 Typical characteristics 16 W Wearing parts 28 ...

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